F68A Manual 060110 Manuals/F60...December 5, 2008 Rev 5 F68A MULTI PURPOSE MACHINING CENTER MACHINE...

December 5, 2008 Rev 5

F68A MULTI PURPOSE MACHINING CENTER

MACHINE SERIAL NUMBER

___________________________

OPERATIONS AND MAINTENANCE MANUAL

MANUFACTURED BY:

ROTTLER MANUFACTURING COMPANY 8029 South 200th Street Kent Washington 98032

USA

Phone: (253) 872-7050 Fax: (253) 395-0230

Website: http://www.rottlermfg.com

NOTE: WHEN ORDERING REPLACEMENT PARTS, PLEASE GIVE THE MODEL AND SERIAL NUMBER.

ORDER BY PART NUMBER.

THERE IS A MINIMUM ORDER OF $25.00

Table of Contents 1 F68A Manual

CHAPTER 1 INTRODUCTION / SAFETY / INSTALLATION: .................................................................................. 1-1

INTRODUCTION: ......................................................................................................................................................... 1-1 DESCRIPTION: ............................................................................................................................................................ 1-1 LIMITED WARRANTY: .................................................................................................................................................. 1-1

Safety Information: ............................................................................................................................................ 1-2 SAFETY INSTRUCTIONS FOR MACHINE USE ....................................................................................................................... 1-2 ELECTRICAL POWER:.................................................................................................................................................... 1-3

Machine Operator: ............................................................................................................................................ 1-4 Emergency Procedure: ....................................................................................................................................... 1-4

MACHINE INSTALLATION: ............................................................................................................................................. 1-5 Location: ............................................................................................................................................................ 1-5 Unpacking and Lifting: ....................................................................................................................................... 1-5

Type One: ................................................................................................................................................................................... 1-6 Type Two: ................................................................................................................................................................................... 1-6

Leveling and Alignment: .................................................................................................................................... 1-7 Leveling Locations: .................................................................................................................................................................... 1-8

Air Supply: .......................................................................................................................................................... 1-9 Grounding: ....................................................................................................................................................... 1-10

Electrical Enclosure: ................................................................................................................................................................ 1-11 GETTING STARTED: ................................................................................................................................................... 1-12

Shipping Restraints: ......................................................................................................................................... 1-15 Spindle Support: ............................................................................................................................................... 1-15 Counter-Weight Bar and Bolt: ......................................................................................................................... 1-16

CHAPTER 2 CONTROL DEFINITIONS: .............................................................................................................. 2-1

COMPUTER AND CONTROLLER DEFINITION: ..................................................................................................................... 2-1 Master Power On/Off Switch: ............................................................................................................................ 2-1 Power Air Draw Bar Switch: ............................................................................................................................... 2-1

INITIALIZATION SCREEN: ............................................................................................................................................... 2-1 GENERAL INFORMATION: ............................................................................................................................................. 2-2

Block Select: ....................................................................................................................................................... 2-3 Select and Continue: ................................................................................................................................................................. 2-3 New Block Model:...................................................................................................................................................................... 2-3 Edit Block Model: ....................................................................................................................................................................... 2-3 Delete Block: .............................................................................................................................................................................. 2-3

Mode Select: ...................................................................................................................................................... 2-4 CYLINDER BORE 3 AXIS: ............................................................................................................................................... 2-5

Through Bore: .................................................................................................................................................... 2-5 Set Zero Tab: .............................................................................................................................................................................. 2-5 Actual Position: .......................................................................................................................................................................... 2-5

Velocity Override: .............................................................................................................................................. 2-5 Zero Buttons: ............................................................................................................................................................................. 2-5 Handwheel Buttons: .................................................................................................................................................................. 2-5 Spindle Start: .............................................................................................................................................................................. 2-6 CW and CCW Creep: .................................................................................................................................................................. 2-6 Jog Buttons: ............................................................................................................................................................................... 2-6 Home Machine: ......................................................................................................................................................................... 2-6 Move To Zeros: .......................................................................................................................................................................... 2-6 CW and CCW Index: ................................................................................................................................................................... 2-6

IMPORTANT: .............................................................................................................................................................. 2-6 Setting Spindle Index: ................................................................................................................................................................ 2-6 Probe Auto Center: .................................................................................................................................................................... 2-6

VERTICAL STOPS TAB: .................................................................................................................................................. 2-7 Move to Vertical Centering Position: ................................................................................................................. 2-8 Lower Clearance Bore: ....................................................................................................................................... 2-8

LEFT AND RIGHT LOCATIONS TAB: .................................................................................................................................. 2-9


Cylinder Bore – Bore Locations ................................................................................................................................................ 2-9 Blueprint: ........................................................................................................................................................... 2-9 Move Buttons: ................................................................................................................................................... 2-9

Bore Buttons: ........................................................................................................................................................................... 2-10 Indicated: ......................................................................................................................................................... 2-10 Set Buttons:...................................................................................................................................................... 2-10 Copy from Blueprint: ........................................................................................................................................ 2-10 Copy from Probed: ........................................................................................................................................... 2-10 Difference: ....................................................................................................................................................... 2-10 Bore Buttons: ................................................................................................................................................... 2-11 Bore Left and Right: ......................................................................................................................................... 2-11 Probing: ........................................................................................................................................................... 2-11 Probe Buttons: ................................................................................................................................................. 2-11 Probe Left or Right: .......................................................................................................................................... 2-11 Actual Diameter: .............................................................................................................................................. 2-11

LIFTER BORE: ........................................................................................................................................................... 2-12 TAPPING: ................................................................................................................................................................ 2-12

Manual Tapping:.............................................................................................................................................. 2-12 FWD: ................................................................................................................................................................ 2-12 REV: .................................................................................................................................................................. 2-12 Hard (Rigid) Tapping: ....................................................................................................................................... 2-13

CYLINDER BORE 4 AXIS: ............................................................................................................................................. 2-14 Through Bore: .................................................................................................................................................. 2-14

Set Zero Tab: ............................................................................................................................................................................ 2-14 Jog Controls: .................................................................................................................................................... 2-14 4

Th-: .................................................................................................................................................................. 2-14

4Th+

: .................................................................................................................................................................. 2-14 4th Axis Degree and Move: .............................................................................................................................. 2-14 4th axis Brake: ................................................................................................................................................. 2-14 Light Clamp: ..................................................................................................................................................... 2-14 Full Clamp: ....................................................................................................................................................... 2-15 Retract: ............................................................................................................................................................ 2-15

CHAPTER 3 OPERATING INSTRUCTIONS: ........................................................................................................ 3-1

LOADING A BLOCK: ..................................................................................................................................................... 3-1 Performance Fixture 650-3-1 Boring: ................................................................................................................ 3-1 Performance Fixture 650-3-1 Lifter Boring: ....................................................................................................... 3-4 Lower End Machining Package 650-3-1A: ........................................................................................................ 3-5 Block End Truing Fixture 650-3-30: .................................................................................................................... 3-7 Block End Truing Fixture 650-3-30 when used with Cam Boring: .................................................................... 3-11 Cam Tunnel Boring: ......................................................................................................................................... 3-12

650-3-20A PAN RAIL WEDGE FIXTURE........................................................................................................................ 3-13 Installation and Operation ...................................................................................................................................................... 3-13 Loading the block: ................................................................................................................................................................... 3-14 Switching banks: ...................................................................................................................................................................... 3-15

V6/V8 Manual Fixture Assembly 502-1-72H: ................................................................................................... 3-16 USING THE 4

TH AXIS FIXTURE: ...................................................................................................................................... 3-23

Loading an engine block: ........................................................................................................................................................ 3-24 Readjusting tailstock piston alignment: ................................................................................................................................. 3-25

GENERAL MACHINE INFORMATION: ............................................................................................................................. 3-27 Homing: ........................................................................................................................................................... 3-27

BUILDING PROGRAMS: .............................................................................................................................................. 3-27 CYLINDER BORE MODE 3 AXIS: ................................................................................................................................... 3-27

Setting Zeros: ........................................................................................................................................................................... 3-27 Horizontal and In/Out Zero:.................................................................................................................................................... 3-27 Vertical Zero: ............................................................................................................................................................................ 3-28


BLUEPRINTING: ........................................................................................................................................................ 3-28 Programming Vertical Stops: ........................................................................................................................... 3-28 Block Clearance: ............................................................................................................................................... 3-28 Centering Height: ............................................................................................................................................. 3-29 Start Boring Height: ......................................................................................................................................... 3-29 Lower Clearance Bore: ..................................................................................................................................... 3-29 Bottom of the Bore: ......................................................................................................................................... 3-30 Probe Height: ................................................................................................................................................... 3-30 Bore Locations: ................................................................................................................................................ 3-31 Boring a Block: ................................................................................................................................................. 3-33

Vertical Zero: ............................................................................................................................................................................ 3-33 INDICATING: ............................................................................................................................................................ 3-33

Programming Vertical Stops: ........................................................................................................................... 3-33 Block Clearance: ............................................................................................................................................... 3-34 Centering Height: ............................................................................................................................................. 3-35 Start Boring Height: ......................................................................................................................................... 3-35 Lower Clearance Bore: ..................................................................................................................................... 3-35 Bottom of the Bore: ......................................................................................................................................... 3-37 Probe Height: ................................................................................................................................................... 3-37 Bore Locations: ................................................................................................................................................ 3-38 Boring a Block: ................................................................................................................................................. 3-40

Vertical Zero: ............................................................................................................................................................................ 3-40 PROBING: ............................................................................................................................................................... 3-40

Programming Vertical Stops: ........................................................................................................................... 3-40 Block Clearance: ............................................................................................................................................... 3-41 Centering Height: ............................................................................................................................................. 3-42 Start Boring Height: ......................................................................................................................................... 3-42 Lower Clearance Bore: ..................................................................................................................................... 3-42 Bottom of the Bore: ......................................................................................................................................... 3-43 Probe Height: ................................................................................................................................................... 3-43 Bore Locations: ................................................................................................................................................ 3-44 Automatic Probing Procedure: ......................................................................................................................... 3-44 Boring a Block: ................................................................................................................................................. 3-45

CYLINDER BORE MODE 4TH AXIS: ................................................................................................................................ 3-45 Setting Zeros: ........................................................................................................................................................................... 3-45

4th

Axis Zero: .................................................................................................................................................... 3-45 Finding the Centerline Zero: ............................................................................................................................. 3-45

Horizontal and In/Out Zero:.................................................................................................................................................... 3-46 Vertical Zero: ............................................................................................................................................................................ 3-47

BLUEPRINTING: ........................................................................................................................................................ 3-47 Programming Vertical Stops: ........................................................................................................................... 3-47 Block Clearance: ............................................................................................................................................... 3-47 Centering Height: ............................................................................................................................................. 3-48 Start Boring Height: ......................................................................................................................................... 3-48 Lower Clearance Bore: ..................................................................................................................................... 3-48 Bottom of the Bore: ......................................................................................................................................... 3-49 Probe Height: ................................................................................................................................................... 3-49 Bore Locations: ................................................................................................................................................ 3-50 Block Angle: ..................................................................................................................................................... 3-50 Boring a Block: ................................................................................................................................................. 3-52

Vertical Zero: ............................................................................................................................................................................ 3-52 INDICATING: ............................................................................................................................................................ 3-52

Programming Vertical Stops: ........................................................................................................................... 3-52 Block Clearance: ............................................................................................................................................... 3-53 Centering Height: ............................................................................................................................................. 3-54


Start Boring Height: ......................................................................................................................................... 3-54 Lower Clearance Bore: ..................................................................................................................................... 3-54 Bottom of the Bore: ......................................................................................................................................... 3-56 Probe Height: ................................................................................................................................................... 3-56 Bore Locations: ................................................................................................................................................ 3-57 Boring a Block: ................................................................................................................................................. 3-59

Vertical Zero: ............................................................................................................................................................................ 3-59 PROBING: ............................................................................................................................................................... 3-59

Programming Vertical Stops: ........................................................................................................................... 3-59 Block Clearance: ............................................................................................................................................... 3-60 Centering Height: ............................................................................................................................................. 3-61 Start Boring Height: ......................................................................................................................................... 3-61 Lower Clearance Bore: ..................................................................................................................................... 3-61 Bottom of the Bore: ......................................................................................................................................... 3-62 Probe Height: ................................................................................................................................................... 3-62 Bore Locations: ................................................................................................................................................ 3-63 Automatic Probing Procedure: ......................................................................................................................... 3-63 Boring a Block: ................................................................................................................................................. 3-64

TAPPING 3 AND 4 AXIS: ............................................................................................................................................. 3-65 Set Zeroes: ....................................................................................................................................................... 3-65 Manual Tapping:.............................................................................................................................................. 3-65 Hard Tapping: .................................................................................................................................................. 3-65

MILL MODE 3 AXIS: .................................................................................................................................................. 3-66 Setting Zeros: ................................................................................................................................................... 3-66

Horizontal Zero: ....................................................................................................................................................................... 3-66 In/Out Zero: ............................................................................................................................................................................. 3-66 Vertical Zero: ............................................................................................................................................................................ 3-66 Example: ................................................................................................................................................................................... 3-66

Mill cut Parameters: ........................................................................................................................................ 3-68 End: ........................................................................................................................................................................................... 3-68 Rough Settings: ........................................................................................................................................................................ 3-68 Total Depth: ............................................................................................................................................................................. 3-68 Amount Per Pass:..................................................................................................................................................................... 3-68

Auto Cycle: ....................................................................................................................................................... 3-68 Final Pass Settings: .................................................................................................................................................................. 3-69 Final Pass Amount: .................................................................................................................................................................. 3-69

Running the Auto Cycle: ................................................................................................................................... 3-69 MILL MODE 4

TH AXIS:................................................................................................................................................ 3-70

Setting Zeros: ................................................................................................................................................... 3-70 Horizontal Zero: ....................................................................................................................................................................... 3-70 In/Out Zero: ............................................................................................................................................................................. 3-70 Vertical Zero: ............................................................................................................................................................................ 3-70 Example: ................................................................................................................................................................................... 3-71

Mill cut Parameters: ........................................................................................................................................ 3-72 End: ........................................................................................................................................................................................... 3-72 Rough Settings: ........................................................................................................................................................................ 3-72 Total Depth: ............................................................................................................................................................................. 3-72 Amount Per Pass:..................................................................................................................................................................... 3-72

Auto Cycle: ....................................................................................................................................................... 3-72 Final Pass Settings: .................................................................................................................................................................. 3-73 Final Pass Amount: .................................................................................................................................................................. 3-73

Move Left and Right: ....................................................................................................................................... 3-73 Cut Left and Right: ........................................................................................................................................... 3-73 Running the Auto Cycle: ................................................................................................................................... 3-73

LIFTER BORE MODE 3 AXIS: ........................................................................................................................................ 3-74 Setting Zeros: ................................................................................................................................................... 3-74

Horizontal Zero: ....................................................................................................................................................................... 3-74


In / Out Zero: ........................................................................................................................................................................... 3-75 Vertical Zero: ............................................................................................................................................................................ 3-76

BLUEPRINTING: ........................................................................................................................................................ 3-76 Programming Vertical Stops: ........................................................................................................................... 3-76

Block Clearance: ...................................................................................................................................................................... 3-76 Centering Height: ..................................................................................................................................................................... 3-77 Start Boring Height: ................................................................................................................................................................. 3-77 Bottom of Bore: ....................................................................................................................................................................... 3-77

Probe Height: ................................................................................................................................................... 3-78 Programming Horizontal Stops:....................................................................................................................... 3-79 Programming In/Out Stops: ............................................................................................................................. 3-79 Running the Auto Cycle: ................................................................................................................................... 3-79

LINE BORE MODE: .................................................................................................................................................... 3-80 Mounting and Aligning the 90 Degree Head: .................................................................................................. 3-80 Setting Zeros: ................................................................................................................................................... 3-80

Horizontal Zero: ....................................................................................................................................................................... 3-81 In/Out and Vertical Zero: ........................................................................................................................................................ 3-81

Programming Vertical Stops: ........................................................................................................................... 3-82 Bore Centerline: ....................................................................................................................................................................... 3-82 Block Clearance: ...................................................................................................................................................................... 3-82

Programming Horizontal Stops:....................................................................................................................... 3-82 Programming Bore Length:.............................................................................................................................. 3-82 Programming In/Out Stops: ............................................................................................................................. 3-82 Running the Auto Cycle: ................................................................................................................................... 3-82

THRUST CUTTING: .................................................................................................................................................... 3-83 Setting Zeros: ................................................................................................................................................... 3-83 Horizontal Zero: ............................................................................................................................................... 3-83 Dimensions & Auto Cycle: ................................................................................................................................ 3-83

THRUST DIMENSIONS: ............................................................................................................................................... 3-84 Outside: .................................................................................................................................................................................... 3-84 Inside: ....................................................................................................................................................................................... 3-84 Cutter: ...................................................................................................................................................................................... 3-84

CLEARANCES: ........................................................................................................................................................... 3-84 Vertical: .................................................................................................................................................................................... 3-84 Horizontal: ................................................................................................................................................................................ 3-84

DIMENSIONS:........................................................................................................................................................... 3-84 Main Width: ............................................................................................................................................................................. 3-84 Insert Width: ............................................................................................................................................................................ 3-84 Left Depth of Cut: .................................................................................................................................................................... 3-84 Right Depth of Cut: .................................................................................................................................................................. 3-85 Feed Through: .......................................................................................................................................................................... 3-85 Rapid Through: ........................................................................................................................................................................ 3-85 Cut Right Side: .......................................................................................................................................................................... 3-85 Cut Left Side: ............................................................................................................................................................................ 3-85

Description and Running of the Auto Cycle: .................................................................................................... 3-85 Start Auto Cycle: ...................................................................................................................................................................... 3-85

Cam End Tunnel Boring: ................................................................................................................................... 3-86 Cam Tunnel Boring: ......................................................................................................................................... 3-87

Zeroing the Micrometer: ......................................................................................................................................................... 3-88 Setting Cutting Size:................................................................................................................................................................. 3-88 Setting Vertical Stops: ............................................................................................................................................................. 3-91 Setting Horizontal Stops:......................................................................................................................................................... 3-91 Auto Cycle: ............................................................................................................................................................................... 3-91 Manual Bore: ........................................................................................................................................................................... 3-91 Recommended Boring Procedure: ......................................................................................................................................... 3-91

CON ROD: ............................................................................................................................................................... 3-92 Manual Screen ......................................................................................................................................................................... 3-92 Setting In/Out and Horizontal Zero ........................................................................................................................................ 3-92


Setting Vertical Zero ................................................................................................................................................................ 3-93 Program Screen ....................................................................................................................................................................... 3-94 Automatic Screen .................................................................................................................................................................... 3-95 Set up procedure for conrod fixture ...................................................................................................................................... 3-96

CHAPTER 4 MAINTENANCE: .......................................................................................................................... 4-1

LUBRICATION ............................................................................................................................................................. 4-1 Automatic Lubrication System ........................................................................................................................... 4-1 Power Draw Bar Lubrication: ............................................................................................................................. 4-1 Probe “On-Center” Adjustment: ........................................................................................................................ 4-2

Step 1 - Adapter Assembly: ....................................................................................................................................................... 4-2 Step 2 – Probe / shank Mounting: ............................................................................................................................................ 4-2 Step 3 – Adjustment: ................................................................................................................................................................. 4-2

LEVELING AND ALIGNMENT: .......................................................................................................................................... 4-4 Leveling the Machine: ........................................................................................................................................ 4-4 Alignment: ......................................................................................................................................................... 4-5 Middle Leveling Bolts: ........................................................................................................................................ 4-8 Sweeping the Spindle: ...................................................................................................................................... 4-10 Vertical Gib Adjustment: .................................................................................................................................. 4-12 Tightening Gibs: ............................................................................................................................................... 4-12 Loosening Gibs: ................................................................................................................................................ 4-12 Performance Fixture Line-Up: .......................................................................................................................... 4-13 Performance Fixture Line-Up (Cam End Tunnel Boring): ................................................................................. 4-14

TO COPY BLOCK INFO FROM YOUR MACHINE: .................................................................................................................. 4-15 TO INSTALL BLOCK INFO ONTO YOUR MACHINE:............................................................................................................... 4-15

CHAPTER 5 TROUBLESHOOTING: ................................................................................................................... 5-1

CHAPTER 6 MACHINE PARTS: ........................................................................................................................ 6-1

F68A FRONT VIEW: .................................................................................................................................................... 6-1 DRIVE MOTORS AND SWITCHES: .................................................................................................................................... 6-2 F68A LEFT SIDE VIEW: ................................................................................................................................................ 6-3 F68A RIGHT SIDE VIEW: .............................................................................................................................................. 6-4 F68A TOP VIEW: ....................................................................................................................................................... 6-5 ELECTRICAL PANEL: ..................................................................................................................................................... 6-6

Computer Enclosure 650-1-27X: ........................................................................................................................ 6-7 Computer 650-7-1: ............................................................................................................................................. 6-8

F68A Control Panel: ................................................................................................................................................................... 6-9 UPPER BELT HOUSING: .............................................................................................................................................. 6-10 CHIP SHIELD ASSEMBLY 650-2-27H: ........................................................................................................................... 6-11

CHAPTER 7 OPTIONS: ................................................................................................................................... 7-1

PERFORMANCE FIXTURE 650-3-1: ................................................................................................................................ 7-1 LIFTER BORE SPACERS: ................................................................................................................................................ 7-2

Application Chart: .............................................................................................................................................. 7-2 CAM BEARING LOCATORS: ............................................................................................................................................ 7-3

Application / Selection Chart: ............................................................................................................................ 7-3 MAIN BEARING LOCATORS: .......................................................................................................................................... 7-4

Selection List: ..................................................................................................................................................... 7-4 Spacer Set for Honda, Subaru and Mitsubishi Blocks 650-3-4F: ............................................................................................ 7-6

AUTOMATIC 4TH

AXIS BLOCK ROLL OVER FIXTURE 650-3-59: ............................................................................................. 7-8 4

TH AXIS HEADSTOCK: .................................................................................................................................................. 7-9

4TH AXIS HEADSTOCK (CONT): .................................................................................................................................... 7-10 4TH AXIS TAILSTOCK: ................................................................................................................................................ 7-11 4TH AXIS TAILSTOCK (CONT): ...................................................................................................................................... 7-12


5” RISER FOR 4TH

AXIS HEAD AND TAIL STOCK: ............................................................................................................... 7-13 CAM AND MAIN LOCATOR INSTALLATION: ..................................................................................................................... 7-14 CAM AND MAIN BEARING LOCATOR SETS FOR 4

TH AXIS ROLL OVER: ................................................................................... 7-14

Individual Main Locators for 4th

Axis: ..................................................................................................................................... 7-15 Individual Cam Locators for 4

th Axis: ...................................................................................................................................... 7-16

LOWER END MACHINING PACKAGE 650-3-1A: .............................................................................................................. 7-18 BLOCK END TRUING FIXTURE 650-3-30: ...................................................................................................................... 7-19 LINE BORE PIVOT TABLE 650-3-56: ............................................................................................................................ 7-20 PAN RAIL WEDGE FIXTURE 650-3-20A........................................................................................................................ 7-21 650-3-44R SMALL PRECISION CONNECTING ROD FIXTURE .............................................................................................. 7-22 650-3-44R SMALL PRECISION CONNECTING ROD FIXTURE – CONTROL PANEL .................................................................... 7-23 650-3-44R SMALL PRECISION CONNECTING ROD FIXTURE – SMALL FRAME ....................................................................... 7-24 650-3-44R SMALL PRECISION CONNECTING ROD FIXTURE – CLAMP ARM ASSEMBLY ........................................................... 7-25 650-3-44R SMALL PRECISION CONNECTING ROD FIXTURE – CARRIAGE ASSEMBLY .............................................................. 7-26 ECONOMY FIXTURE 7241P: ....................................................................................................................................... 7-27 2 ½” WEAR PAD ASSEMBLY 650-3-34: ....................................................................................................................... 7-28 MANUAL V6/V8 COMBINATION FIXTURE 502-1-72H: ................................................................................................... 7-29

Boring Machine Application ............................................................................................................................ 7-29 V-blocks: .......................................................................................................................................................... 7-29 Y-Blocks: ........................................................................................................................................................... 7-29 Normal Operating Procedure:.......................................................................................................................... 7-29

MANUAL FIXTURE ASSEMBLY 502-1-72H: ................................................................................................................... 7-32 V6/V8 MANUAL FIXTURE BODY ASSEMBLY 502-1-72J: ................................................................................................. 7-33 V6/V8 MANUAL FIXTURE BODY ASSEMBLY 502-1-72J: (CONT) ....................................................................................... 7-34 BLOCK HANDLER 502-1-95: ...................................................................................................................................... 7-36 DUAL AXIS LEVELING TABLE 7209M: ........................................................................................................................... 7-37

Adjustment Procedure: .................................................................................................................................... 7-42 LUBRICATION: .......................................................................................................................................................... 7-45 UNIVERSAL TOOLING PACKAGE 7119P: ........................................................................................................................ 7-46 EXHAUST/INTAKE MANIFOLD SURFACING FIXTURE ASSEMBLY 7226G: ............................................................................... 7-47 EXHAUST/INTAKE MANIFOLD FIXTURE: ......................................................................................................................... 7-48

Instructions ...................................................................................................................................................... 7-48 Exhaust Manifolds ................................................................................................................................................................... 7-48

TYPICAL EXHAUST MANIFOLD SET-UP: .......................................................................................................................... 7-49 TYPICAL EXHAUST MANIFOLD SET-UP: .......................................................................................................................... 7-49

Intake Instructions: .......................................................................................................................................... 7-50 Typical Intake Manifold Set-up: ....................................................................................................................... 7-51

DUAL AXIS LEVEL ASSEMBLY 7125A: ........................................................................................................................... 7-52 Level Intake and Exhaust Manifold 650-3-38: ....................................................................................................................... 7-54 Combination Grit Sharpening Stone 650-2-11H: .................................................................................................................. 7-54

3 DIMENSIONAL ELECTRONIC POSITION FINDER 650-2-44Q: ........................................................................................... 7-55 Renishaw Wireless Probing System 650-3-59J: ..................................................................................................................... 7-56

½” CLAMP KIT: ........................................................................................................................................................ 7-57 MAGNETIC INDICATOR HOLDER 502-12-4: ................................................................................................................... 7-58 MAGNETIC INDICATOR HOLDER 502-12-4A: ................................................................................................................ 7-59 502-12-4 MAGNETIC HOLDER ASSEMBLY: .................................................................................................................. 7-59 LIFTER BORE TOOLING KIT 6648H:.............................................................................................................................. 7-60

Chevrolet Lifter Bore Tooling Package 650-2-44R: ............................................................................................................... 7-61 Tooling Required for Additional Block models not included in the Chevrolet Package: .................................................... 7-62

QUICK CHANGE TAP HOLDER ASSEMBLY 650-2-11K: ..................................................................................................... 7-63 TORQUE CONTROL TAP HOLDERS: ............................................................................................................................... 7-64 PRECISION DRILL CHUCK ASSEMBLY 650-2-44M: .......................................................................................................... 7-64 2.9” CUTTERHEAD: ................................................................................................................................................... 7-65

2.9” Cutterhead Standard Tooling: .................................................................................................................. 7-66 6520 Series Tool Holders ........................................................................................................................................................ 7-66


6598K Tool Bit when used with 6520 Holders....................................................................................................................... 7-66 6260 Series Tool Bit when used with 6520 Holders .............................................................................................................. 7-66

Cartridge Tool Holders: .................................................................................................................................... 7-67 511-29-12D Torx Wrench ........................................................................................................................................................ 7-67 900-2-20 Universal Digital Micrometer Assembly ................................................................................................................ 7-67

2.9” Cutterhead Optional Tooling: ................................................................................................................... 7-68 6513 Series Grooving Tool Bits ............................................................................................................................................... 7-68 when used with 6520 Holders ................................................................................................................................................ 7-68

6594 Cartridge Tool Holder:............................................................................................................................. 7-68 MISCELLANEOUS TOOLING FOR 650-2-14B CUTTERHEAD: .............................................................................................. 7-69 2.0” CUTTERHEAD: ................................................................................................................................................... 7-70

2.0” Cutterhead Standard Tooling: .................................................................................................................. 7-71 6801 Series Tool Holders........................................................................................................................................................ 7-71 511-29-12F Torx Wrench ........................................................................................................................................................ 7-71 501-72J Hex Driver .................................................................................................................................................................. 7-71 900-2-19 Micrometer Assembly ............................................................................................................................................. 7-72

650-2-16D EXTENDER FOR 650-2-14C CUTTERHEAD: .................................................................................................. 7-72 Right Angle Drive 6753M: ....................................................................................................................................................... 7-73 Extension Spacer for Right Angle Drive Assemblies: ............................................................................................................. 7-74

RIGHT ANGLE DRIVE TOOLING: ................................................................................................................................... 7-75 650-2-39B Line Bore Cutterhead 1.9” to 4.0”: ................................................................................................. 7-75

Micrometer Assembly 900-2-19: ............................................................................................................................................ 7-76 RIGHT ANGLE DRIVE TOOLING: ................................................................................................................................... 7-77

650-2-39C Line Bore Cutterhead 2.9” to 5.6”: ................................................................................................. 7-77 Hex Driver 3/16” 501-72J ................................................................................................................................. 7-78 Torx Wrench 511-29-12D ................................................................................................................................. 7-78

Micrometer Assembly 900-2-19: ............................................................................................................................................ 7-79 Right Angle Drive 650-2-37A: ................................................................................................................................................. 7-80 Special Extended Narrow 90 Degree Line Bore Head 6753N: .............................................................................................. 7-81

Thrust Facing Tool Holder: ............................................................................................................................... 7-83 Thrust Facing Tool Holder: ............................................................................................................................... 7-83 10” Surfacing Head w/ Tooling: ....................................................................................................................... 7-84 14” Surfacing Head w/ Tooling: ....................................................................................................................... 7-85 2 ½” Shell Mill Assembly w/ Tooling: .............................................................................................................. 7-86 4” Shell Mill Assembly w/ Tooling: .................................................................................................................. 7-87 Complete Listing of NMTB 40 Taper Shell Mill Arbors: .................................................................................... 7-87

CAM LINE BORING TOOLING PACKAGE:......................................................................................................................... 7-88 1.9” Cutterhead: .............................................................................................................................................. 7-88 511-29-12F Torx Wrench: ................................................................................................................................ 7-89 501-72A Hex Driver: ......................................................................................................................................... 7-89 900-2-19 Micrometer Assembly:...................................................................................................................... 7-90 Oil Groove Tooling 650-2-32K: ......................................................................................................................... 7-90 Cam Locator Support: ...................................................................................................................................... 7-91 Block Clamp: .................................................................................................................................................... 7-92 Block Clamp Stud: ............................................................................................................................................ 7-92 Adapter and Dual Flex Coupling Assembly: ..................................................................................................... 7-92 Cam Line Boring Bar: ....................................................................................................................................... 7-93 650-2-32D ........................................................................................................................................................ 7-93 Cam Line Bore Bushings: .................................................................................................................................. 7-93 Cam Line Boring Cartridges: ............................................................................................................................ 7-94 Tool Setting Indicator: ..................................................................................................................................... 7-94 Wrenches: ........................................................................................................................................................ 7-94

Introduction / Safety / Installation 1-1 F68A Manual

Chapter 1 Introduction / Safety / Installation: Introduction: This manual is arranged in sections as listed in the table of contents. It is required that the new user of the F68A Boring Machine read this manual before operation. Pay close attention to the sections concerning safety. The Controls Definition and Operating Instructions chapters should be read very carefully in order to familiarize the user with the actual button pushing sequences required to carry out a job. These chapters in the manual should be considered an introduction. As the operators of the F68A series machine gains experience with using different functions of the machine, complicated setups and programs will make more sense. The rest of the manual contains information and part number reference on fixtures, cutting tools, and machine maintenance. The operator needs to read and become familiar with these areas as well Description: The model F68A is a precision, single point, high speed boring machine. The F68A can be equipped with tooling and accessories for re-boring most American passenger car and truck engines, In-lines as well as 60 and 90 degree V-types. The F68A machines can be easily tooled to machines a wide range of engines, including European and Asian. The machine is designed to maintain the alignment of cylinder bores to the Pan Rails and Main Bearing bore locations, as was done in the original factory machining. This overcomes the many inaccuracies and out-of-alignment problems associated with the clamping of portable boring bars to the cylinder head surface of the blocks. Convenient controls, fast block clamping, air floated Spindle Base positioning and clamping, means considerable savings in floor to floor time and operator involvement. Change over or re-setting time required to set up V-type or In-Line engines is a minimum, making this machine highly suited to the jobber shop where engines cannot be run through in model lots. Limited Warranty: Rottler Manufacturing Company Model F68A parts and equipment is warranted as to materials and workmanship. This limited warranty remains in effect for one year from the date of delivery, provided the machine is owned and operated by the original purchaser and is operated and maintained as per the instructions in the manual. Tools proven to be defective within the warranty period will be repaired or replaced at the factory’s option. We accept no responsibility for defects caused by external damage, wear, abuse, or misuse, nor do we accept any obligation to provide compensation for direct or indirect costs in connection with cases covered by the warranty. Freight charges on warranty items (non-air shipment only) will be paid by Rottler Manufacturing for a period of 60 days only from the date of installation or set-up by a qualified service technician or sales representative. Freight charges after the 60 day period are the customer’s responsibility.

Introduction / Safety / Installation 1-2 F68A Manual Safety Information:

For Your Own Safety Read This Instruction Manual Before Operating This Machine.

This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage.

This machine is capable of causing severe bodily injury.

Safety Instructions for Machine Use KEEP GUARDS IN PLACE and in proper working order. KEEP WORK AREA CLEAN . Cluttered areas and benches invite accidents. KEEP CHILDREN AND VISITORS AWAY . All children and visitors should be kept a safe distance from work area. WEAR THE PROPER APPAREL. DO NOT wear loose clothing, gloves, rings, bracelets, or other jewelry which may get caught in moving parts. Non-Slip foot wear is recommended. Wear protective hair covering to contain long hair. ALWAYS USE SAFETY GLASSES . Also use face or dust mask if cutting operation is dusty. Everyday eye glasses only have impact resistant lenses, they are NOT safety glasses. DO NOT OVER-REACH. Keep proper footing and balance at all times. USE THE RECOMMENDED ACCESSORIES. Consult the manual for recommended accessories. The use of improper accessories may cause risk of injury.

Introduction / Safety / Installation 1-3 F68A Manual CHECK DAMAGED PARTS. Before further use of the machine, a guard or other part that is damaged should be checked to determine that it will operate properly and perform its intended function. Check for alignment of moving parts, breakage of parts, mounting, and other conditions that may affect its operation. A guard or other part that is damaged should be properly repaired or replaced. NEVER OPERATE A MACHINE WHEN TIRED, OR UNDER THE INFLUENCE OF DRUGS OR ALCOHOL. Full mental alertness is required at all times when running a machine. NEVER ALLOW UNSUPERVISED OR UNTRAINED PERSONNEL TO OPERATE THE MACHINE. Make sure any instructions you give in regards to machine operation are approved, correct, safe, and clearly understood. IF AT ANY TIME YOU ARE EXPERIENCING DIFFICULTIES performing the intended operation, stop using the machine! Then contact our service department or ask a qualified expert how the operation should be performed.

No list of safety guidelines can be complete. Every shop environment is different. Always consider safety first, as it applies to your individual working conditions. Use this and other machinery with caution and respect. Failure to follow guidelines could result in serious personal injury, damage to equipment or poor work results. Electrical Power:

All electrical power should be removed from the machine before opening the rear electrical enclosure. It is recommended that the machine have a electrical LOCK-OUT device installed. Make sure all electrical equipment has the proper electrical overload protection. In the event of an electrical short, grounding reduces the risk of electric shock by providing a path of least resistance to disperse electric current.

Electrocution or a fire can result if the machine is not grounded correctly. Make sure the ground is connected in accordance with this manual. DO NOT operate the machine if it is not grounded.

No single list of electrical guidelines can be comprehensive for all shop environments. Operating this machinery may require additional electrical upgrades specific to your shop environment. It is your responsibility to make sure your electrical system comply with all local codes and ordinances.

When boring the machine is capable of throwing metal chips over 10- feet from the cutting area. Always use the guards. Eye protection must be worn at all times by the operator and all other personnel in the area of the machine.

The F68A operates under computerized control and, as is all computerized equipment, and is susceptible to extraneous electrical impulses internally for externally produced. The

Introduction / Safety / Installation 1-4 F68A Manual machine may make moves out of the operator control at any time. The operator should work in and around the machine with caution at all times. The operator and nearby personnel should be familiar with the location and operation of the Emergency Stop Button. Make sure all electrical equipment has the proper overload protection. The F68A should have a fully isolated power supply to prevent damage and uncontrolled movement of the machine. If the F68A is on the same power lines that are running to other electrical equipment (grinders, welders, and other AC motors) electrical noise can be induced into the F68A electrical system. Electrical noise can cause the controller to see false signals to move. Not supplying a fully isolated supply to the machine may void factory warranty. Refer to the Power supply section later in this chapter for voltage and amperage requirements of the F68A. Machine Operator: The operator of the F68A should be a skilled machinist craftsman who is well versed in the caution, care, and knowledge required to safely operate metal cutting tools. If the operator is not a skilled machinist he/she must pay strict attention to the Operating Instructions outlined in this manual, and get instruction from a qualified machinist in both production and operation of this machine. The F68A machines have the following areas of exposed moving parts that you must train yourself to respect and stay away from when they are in motion:

Cutting Tool Area – Any operation involving hands in the cutter head area, such as inspection or alignment of the cutter head or tools, changing Centering Fingers, tool insertion, and removal, cutter head changes, and size checking etc. requires the machine to be in Neutral.

Machining – Eye protection must be worn during all operations of the machine. Hands must be kept completely away from the cutter head. All chip guards must be in position during machine operations.

Work Loading and Unloading – Carefully develop handling methods of loading and unloading work pieces so that no injury can result if hoist equipment or lift connection should fail. Periodically check lift components for damage that may cause failure of Block Handler Assembly. Lifting Eye can eventually fail if the eye is reset in line with the 502-1-80 lift channel. Eye must be at a right angle.

Machine Maintenance – Any machine adjustment, maintenance or parts replacement absolutely requires a complete power disconnection from the machine, this is an absolute rule. Emergency Procedure: Assuming one of the following has occurred: tool bit set completely off size, work piece or spindle base not clamped, spindle is not properly centered, and these mistakes will become obvious the minute the cut starts PRESS THE EMERGENCY STOP BUTTON (on the front control panel) IMMEDIATELY!

Introduction / Safety / Installation 1-5 F68A Manual Find out what the problem is; return the spindle to its up position without causing more damage. To restart the machine, turn the Emergency Stop Button CW until the button pops out. Make sure the button has been depress for at least 1 ½ minutes or the drive will not have time to reset and they will not function. Be alert to quickly stop the machine in the event of a serious disruption of the boring process either at the top or bottom of the bores. “REMEMBER” metal cutting tools have the speed and torque to severely injure any part of the human body exposed to them. Machine Installation: Location: The productivity of the F68A will depend a great deal on the proper initial installation. Pay particular attention to the means by which work pieces are lifted into and out of the machine as well as the material handling to and from other operations in your shop. The proper loading arrangements and work location for your F68A is extremely important. A slow travel (6’ to 10’ per minute) power hoist, operated from either a bridge or jib crane arrangement works very well. A 1000 lb. Is generally adequate for lifting most engine blocks. An air hoist with speed control makes an ideal method for fast, efficient loading and unloading. For shops where large production runs are anticipated, the work pieces should be loaded and unloaded directly from a conveyer. If this is not the case, we suggest you pay considerable attention to the crane so that it covers an adequate area to allow the operator to back up and remove work pieces without creating a cluttered, dangerous work area. Unpacking and Lifting: Use care when removing the crate materials from the machine. Be careful not to use force on any part of the machine. Remove the Nuts and Jam Nuts from the Four (4) bolts holding the F68A to the crate. These bolts are located at the four bottom corners of the Main Base. You will need a Fork Truck with a minimum of 8,000 lb. Capacity. The F68A can be picked up from the pallet in two (2) different ways. See the following page for illustration of these procedures.

Introduction / Safety / Installation 1-6 F68A Manual Type One:

Be sure that the forks are at least Four inches through the opposite side of the casting.

This machine is extremely top heavy. Use extreme care whenever this machine is being used. Do not use quick or sharp movement. Type Two:

Introduction / Safety / Installation 1-7 F68A Manual Remove the Toolbox, Parallels and optional equipment form the machine. Completely clean these articles along with the rest of the machine with solvent, rust inhibitor was applied at the time of shipment. Any of the rust inhibitor left on the machine will allow Cast Iron dust to build up and cause premature wear to the machine. IMPORTANT: The ways under the table as well as the ways behind the Vertical gibs were sprayed with rust inhibitor as well. It is extremely important that these surfaces be cleaned thoroughly. Use a cleaner, such as WD-40 to clean the ways where the table and the spindle unit are not sitting. Move the table and spindle unit onto the area that has been cleaned and clean where they were sitting. S

F68A Manual 060110 Manuals/F60...December 5, 2008 Rev 5 F68A MULTI PURPOSE MACHINING CENTER MACHINE...

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Transcript of F68A Manual 060110 Manuals/F60...December 5, 2008 Rev 5 F68A MULTI PURPOSE MACHINING CENTER MACHINE...